Gutter Cover Manufacturing Apparatus

ABSTRACT

Methods and apparatus for fabricating articles having apertures from a flat feedstock, such as gutter covers, are provided herein. In some embodiments, an apparatus for fabricating articles having apertures from a flat feedstock includes an uncoiler for receiving and metering out a desired quantity of a flat feedstock in roll form; a feeder/straightener for receiving the feedstock from the uncoiler; a first press for receiving the feedstock from the feeder/straightener, the first press housing a tool and die that forms one or more apertures in the feedstock; a second press for receiving the feedstock from the first press, the second press housing a tool and die that cuts the feedstock into a finished length; and a roll former for receiving the feedstock from the second press, the roll former comprising a plurality of rollers that create a desired profile along the width of the feedstock.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional PatentApplication entitled “GUTTER COVER MANUFACTURING APPARATUS”, Ser. No.60/747,555, filed May 18, 2006, which is hereby incorporated byreference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

Embodiments of the present invention generally relate to the manufactureof gutter covers. More specifically, embodiments of the presentinvention generally relate to manufacturing apparatus for themanufacture of gutter covers.

2. Description of the Related Art

Gutter covers, such as those depicted in U.S. Pat. No. 5,339,575 andD382,944, have conventionally been fabricated using a variety ofapparatus. In one conventional embodiment, gutter covers may befabricated using a turret press. In this manner of manufacture, flatmetal sheets are sheared to specified sizes and then manually insertedinto the turret press to fabricate the apertures one hole at a time. Thefabricated sheet with prescribed apertures is then formed withprescribed radius bends in a manually operated brake. Due to the natureof the manual brake, each radius bend is formed one at a time.

This method of fabrication is very time consuming and has high risk ofvariations in the finished product. For example, it has been found thatforming radius bends utilizing a manual brake may lead to production ofup to 4% off-spec material. While technology exists to automate feeds tothe turret press, the size and weight of the equipment limits it toprincipally being operated by machine shops with highly skilled repairtechnicians.

In another conventional manufacturing method, gutter covers may befabricated using a punch and die apparatus containing a series ofmanufacturing elements. In this embodiment, flat metal feedstock in coilform is introduced into a feeder which straightens the metal, which issubsequently fed in a prescribed length to a large press that forms theapertures and cuts the cover to a prescribed length. The fabricatedsheet with prescribed apertures is then formed with prescribed radiusbends one at a time in a manually operated break as described above.

While this method of manufacture is faster than the turret press, thesize of the equipment limits production to machine and specialty shopsemploying highly skilled technicians.

Another problem associated with these conventional fabrication apparatusis that the extremely large size and weight (approximately four tons) ofboth the punch and die press and the turret press requires specialrigging companies to transport and deliver the equipment. In addition,the turret presses and presses required to operate the tool and die areexpensive and require a large investment. Moreover, the sophisticationof the equipment also limits manufacture to certain specialty or machineshops, thereby requiring substantially more shipping and handlingexpense for the distribution of the rain gutter products.

Therefore, there is a need for a manufacturing apparatus that can beeasily acquired for much less than the cost of equipment previously usedand that may be easily installed in a fabricator's warehouse.

SUMMARY OF THE INVENTION

The present invention generally provides an improved apparatus forfabricating articles having apertures from a flat feedstock, such asgutter covers. The present invention overcomes the disadvantagesassociated with the prior art. Specifically, the present inventionincludes equipment used for fabricating gutter covers which is light inweight as compared to the conventional equipment presently used. The newequipment can easily be moved and installed with typical equipment usedin warehousing, such as a fork lift.

In some embodiments, an apparatus for fabricating articles havingapertures from a flat feedstock includes an uncoiler for receiving andmetering out a desired quantity of a flat feedstock in roll form; afeeder/straightener for receiving the feedstock from the uncoiler; afirst press for receiving the feedstock from the feeder/straightener,the first press housing a tool and die that forms one or more aperturesin the feedstock; a second press for receiving the feedstock from thefirst press, the second press housing a tool and die that cuts thefeedstock into a finished length; and a roll former for receiving thefeedstock from the second press, the roll former comprising a pluralityof rollers that create a desired profile along the width of thefeedstock.

In some embodiments, an apparatus is provided including, in order, anuncoiler, a feeder/straightener, a first press, a second press, a rollformer, a collection table, and a control module. An input material,such as a flat metal sheet in roll form, is loaded onto the uncoiler andis fed to the straightener/feeder. The straightener/feeder moves thematerial through a series of rollers which bends the flat metal inopposing directions removes any curl or memory the metal may have frombeing stored in coiled form. The feeder portion of thefeeder/straightener measures and delivers a specified length of thematerial to the two presses in series. The first press houses a tool anddie that pierces and forms the apertures of the gutter cover. The numberof apertures formed with each hit from the press can range from one at atime to any number. The second press houses a tool and die thatseparates the material into a finished length and forms any prescribedapertures and notches specified in the finished parts for installationon a rain gutter such that the individual rain gutter covers overlap andare fastened together. As the part, complete with all apertures formed,leaves the second press in flat form, a set of feed rollers pull thepart into the roll former. The roll former forms the radius bends asspecified for the finished part through a series and combination ofrollers. The finished part exits the roll former and is dropped into thecollection table. The components of the apparatus are equipped withcontrols and instrumentation which automatically counts the number ofhits made on each press, controls each press and feeder, and counts eachpart manufactured for reporting purposes. Alternatively, the equipmentcan be also operated in manual form without any controlling equipment.

In some embodiments, an apparatus for fabricating articles havingapertures from a flat feedstock includes an uncoiler for receiving andmetering out a desired quantity of a flat feedstock in roll form; afeeder/straightener for receiving the feedstock from the uncoiler; apress for receiving the feedstock from the feeder/straightener, thepress configured to form one or more apertures in the feedstock and tocut the feedstock into a finished length; and a roll former forreceiving the feedstock from the press, the roll former comprising aplurality of rollers that create a desired profile along the width ofthe feedstock.

In some embodiments, an apparatus is provided including, in order, anuncoiler, a feeder/straightener, a press, a roll former, a collectiontable, and a control module. The press contains both a first tool anddie and a retractable second tool and die encapsulated by connectingmembers in one housing unit. The first tool and die is configured toform from one or more apertures with each stroke. The retractable secondtool and die may consist of one or more independent sections that areconfigured to separate the parts and make any apertures or notches thatmay be specified to be located at the end of the parts. The retractablesecond tool and die creates both apertures and notches located at theend of the part of the material being cut off and the beginning of thepart of the material being moved through the press. This apparatus isotherwise similar to the apparatus described above.

In some embodiments, a method of fabricating articles having aperturesfrom a flat feedstock includes providing, in alignment, an uncoiler forreceiving and metering out a desired quantity of a flat feedstock inroll form, a feeder/straightener for receiving the feedstock from theuncoiler, a first press for receiving the feedstock from thefeeder/straightener, and a roll former for receiving the feedstock fromthe press; metering out a desired quantity of a flat feedstock in rollform from the uncoiler to the feeder/straightener; forming one or moreapertures in the straightened feedstock using the first press; cuttingthe feedstock into a finished length; and creating a desired profilealong the width of the feedstock using the roll former.

BRIEF DESCRIPTION OF THE DRAWINGS

The teachings of the present invention will become apparent byconsidering the following detailed description in conjunction with theaccompanying drawings, in which:

FIG. 1 is a schematic plan view showing one embodiment of a gutter coverforming apparatus.

FIG. 2 is a schematic side view of another embodiment of a gutter coverforming apparatus.

FIG. 3 is a schematic plan view showing another embodiment of a guttercover forming apparatus.

FIG. 4 is a schematic plan view showing another embodiment of a guttercover forming apparatus.

FIG. 5 is a schematic plan view showing another embodiment of a guttercover forming apparatus.

FIG. 6 is a schematic plan view showing another embodiment of a guttercover forming apparatus.

FIGS. 7A-B are perspective views of one embodiment of a gutter coverthat may be fabricated with the apparatus of the present invention.

Where possible, identical reference numerals are used herein todesignate identical elements that are common to the figures. The imagesin the drawings are simplified for illustrative purposes and are notdepicted to scale. The appended drawings illustrate exemplaryembodiments of the invention and, as such, should not be considered aslimiting the scope of the invention that may admit to other equallyeffective embodiments.

DETAILED DESCRIPTION

Embodiments of the present invention generally relate to the manufactureof articles having apertures from a flat feedstock. In one illustrativeembodiment, embodiments of the present invention may be utilized tofabricate gutter covers, such as are depicted in U.S. patent Ser. No.5,339,575, issued Aug., 23, 1994, and D382,944, issued Aug. 26, 1997, orany other gutter cover containing one or two rows of apertures (see, forexample, gutter cover 700 depicted in FIGS. 7A-B). The manufacturingapparatus of the present invention is advantageously relatively small insize, can be easily installed without special rigging equipment, and canbe easily operated by a relatively unskilled workman. Although describedbelow in reference to manufacturing gutter covers, it is contemplatedthat the inventive apparatus may be utilized to manufacture otherarticles having apertures from a flat feedstock.

The present invention utilizes a series of readily available equipmentarranged in a specific order to manufacture specified rain gutter coversutilizing flat metal stock available in coil form. These presses arereadily commercially available from companies such as Minster MachineCo, located in Minster, Ohio; Cincinnati, located in Cincinnati, Ohio;Niagara Machine and Tool Works, located in Buffalo, N.Y.; KomatsuIndustries Corp., located in Tokyo, Japan; Chicago Dreis & Krump (D&K),located in Chicago, Ill.; and the like.

FIG. 1 is a schematic showing one embodiment of a gutter cover formingapparatus of the present invention. As depicted in FIG. 1, a guttercover manufacturing apparatus 100 includes an uncoiler 102, afeeder/straightener 104, a first press 106, a second press 108, a rollformer 110, a collection table 112, and a control module 114.

The uncoiler 102 may be a powered uncoiler, such as are commerciallyavailable through companies such as ASC Machine Tools, Inc., of SpokaneValley, Wash., and the like. In addition, uncoilers are typicallyavailable through most metal handling industrial supply houses such asRapid Air, of Rockford, Ill. The uncoiler 102 is typically mountedhorizontally, such that the shaft or mandrel for holding a coil offeedstock, or material, (not shown) is horizontal to the floor. Theuncoiler 102 is typically motorized and controlled by a set of microswitches or a photo beam that controls the uncoiler 102 as itselectively feeds material to the feeder/straightener 104.

Because the feeding speed of the uncoiler 102 may be different than thatof the feeder/straightener 104, there is typically a distance of up toapproximately 6 to 8 feet between the uncoiler 102 and thefeeder/straightener 104 to allow for excess material to drop near thefloor during operation. In operation, as the material drops towards thefloor or a predetermined point near the floor, a micro switch turns offthe feed of material from the uncoiler 102. As the feeder/straightener104 uses up the material, the excess material disposed between theuncoiler 102 and the feeder/straightener 104 raises in elevation to thelocation of a second micro switch which turns on the uncoiler 102,causing it to resume feeding material.

It is contemplated that any method of controlling the uncoiler 102 maybe utilized, including photo cell technology, control arms that may beincluded as a part of uncoiler 102, other arrangements of microswitches, and the like. It is further contemplated that the uncoiler 102and the straightener can be combined in one unit, such as iscommercially available from Tomac Corp., located in Taishan, Taiwan(http://www.toptran.com.tw/cproducts_thin.htm). It is furthercontemplated that the uncoiler 102 may be unmotorized and/or mountedvertically, such as in a pallet reel format, also commercially availablefrom companies such as Rapid Air, of Rockford, Ill., such that eitherthe feeder or straightener or both pull the coil of material from theuncoiler without having the necessity of a loop in the coil to make upfor different speeds of the equipment.

The feeder/straightener 104 may be manufactured as one device whichstraightens as it feeds and removes coil from an unmotorized uncoiler102. The feeder/straightener 104 may be either of a servo feed nature,where the precise rotation of rollers are controlled to deliver aspecific length of material, or air feed, wherein the material isclamped with air pressure by a feeding clamp and advanced for aspecified length at which point the feeding clamp is released and astationery clamp is engaged to keep the material stationary while thefeeding clamp is slid back to a feed position to begin the feed cycleonce again. The stationary clamp is released while the feed clamp isengaged.

The feeder/straightener 104 contains a series of rollers (not shown)disposed on either side (e.g., above and below) the material. As thematerial passes between the rollers, the material is bent in oppositedirections, thereby straightening the material and removing any memoryof the material from having been stored in roll form. The rollers aretypically adjustable to increase or decrease the degree of bend requiredto flatten or straighten the material, although they can be fixed.Typically at least three rollers are provided. However, the number ofrollers may vary.

The feeder portion of the feeder/straightener 104 can be adjusted todeliver a specified length of flat material to the press 106. Thefeeder/straightener 104 is typically controlled by the control module114 such that the feeder/straightener 104 feeds a specified length ofstraightened material to the press 106 during operation.

The press 106 is typically an approximately two-ton or less presscontaining a tool and die for forming one or more apertures in aworkpiece with each stroke of the press 106. The number and arrangementof the apertures is designed into the press 106 as desired to producethe particular end product. For example, the press 106 may be configuredto form one or more apertures 710 as depicted in FIGS. 7A and 7B. Asignal indicating the end of feed from the feeder/straightener 104causes the press 106 to perform a stroke. The feed and stroke seriesoccurs a prescribed number of times as controlled by control module 114.

When the prescribed number of strokes is complete, a signal from thecontrol module 114 is sent to the press 108 causing it to stroke. Thepress 108 may be similar in size to press 106 and contains a tool anddie for cutting the material to a desired length and making anyapertures or notches that may be specified to be located at either theend of the material. The tool and die of the press 108 creates bothapertures and notches located at the end of the part of the materialbeing cut off and the beginning of the part of the material being movedthrough the press 108. For example, in addition to cutting the materialto length, the press 108 may be used to form apertures 720, 734 andnotches 722 as depicted in FIGS. 7A-B. At the completion of the strokeof the press 108, a signal is sent to control module 114 which beginsthe counting sequence once again. Those skilled in the art willrecognize that depending on the number of apertures formed by the press106, the feed length may be altered for the press 108 to causeseparation of the material into parts of a desired length withoutdeviating from the scope of this invention.

As the separated part of the material containing all apertures andnotches leaves the press 108, a feed roller in the front portion of theroll former 110 guides the material into the main body of the rollformer 110. The roll former 110 contains a series of rollers, typicallya minimum of four rollers, that pulls the material through the rollformer 110, thereby causing the material to be gradually be shaped withthe specified radius bends as it exits the end of the roll former 110.For example, the roll former 110 may be configured to bend the materialto form a front ledge 716, a front face 730, and a cover portion 708, asdepicted in FIGS. 7A-B. It is understood that technology for rollforming is well known in the trade and that a roll former suitable forcreating the bends as desired in the finished product may bemanufactured by many different manufacturers with various modifications.

As the finished material leaves the roll former 110 it drops onto thecollection table 112 where finished product is stacked. Optionally, thecontrol module 114 can provide a signal and/or shut down the entiresystem after a prescribed number of parts are stacked, thereby providingtime for manual packaging. It is also recognized that those skilled inthe art may employ robotics controlled by the control module 114 tocollect a prescribed number of parts and package them automatically. Thecontrol module 114 may also provide a confidential count of total partsproduced for calculating royalties with or without automatic reportingfeatures to an outside party. Those skilled in the art will recognizethat presses larger or smaller than a two ton rating may be used toachieve the same results depending on the size of the tooling and numberof apertures being formed by each tool and die without departing fromthe scope of this invention. Optionally, the components of the apparatus100 as described above may be performed manually, without the need forthe control module 114.

Optionally, both the press 106 and the press 108 shown in FIG. 1 may bereplaced with a single press. For example, FIG. 2 depicts a schematicside view of a gutter cover forming apparatus 200. The apparatus 200 issimilar to the apparatus 100 of FIG. 1 except that the press 106 and thepress 108 are replaced by a single press 206.

As shown in FIG. 2, the press 206 is typically an approximately up toten ton press containing a tool and die 214 and a retractable tool anddie 216 encapsulated by connecting members 210 in one housing unit 212.The tool and die 214 is configured to form from one or more apertureswith each stroke. The retractable tool and die 216 may consist of one ormore independent sections that are configured to separate the parts andoptionally to make any apertures or notches that may be specified to belocated at the end of the parts. The independent sections of theretractable tool and die 216 may be disposed adjacent to each other orseparated by other components. The retractable tool and die 216 maycreate both apertures and notches located at the end of the part of thematerial 220 being cut off and the beginning of the part of the material220 being moved through the press 206.

Specifically, an end of feed signal from the feeder/straightener 104causes the press 206 to complete a stroke. With each stroke of the press206, the tool and die 214 is actuated to make apertures in the material220. When a specified number of strokes is complete (e.g., one or more),a signal from control module 114 is sent to feeder/straightener 104causing it to actuate either a gag feed (e.g., feed of a differentlength of material) to the press 206 at which time the retractable die216 is also actuated in whole or part, or the retractable die 216 inwhole or in part without the need for a gag feed.

It is recognized that those skilled in the art may choose to have theretractable die 216 as one integral unit or that it may be divided intotwo independently operated units to separate the material 220 intoseparate parts and accomplish the formation of apertures on the ends ofthe separated part.

After the press 206 completes its stroke, the retractable tool and die216 is retracted for the next stroke or series of strokes by the press206. Those skilled in the art will recognize that by altering the numberof apertures formed by the tool and die 214, arrangement and activationof the retractable tool and die 216, and the gag feed (change in feedlength) can be in any combination without departing from the scope ofthe present invention.

From this point, the separated portion of the material 220 produced bythe retracting tool and die 216 is guided into the roll former 110 asdescribed above with respect to FIG. 1.

FIG. 3 depicts another embodiment of a gutter cover forming apparatus300. The apparatus 300 is similar to the apparatus 100 of FIG. 1 exceptthat the press 108 is replaced with a flying shear 308. In thisembodiment, as the material continuously moves through the press 106,the flying shear 308 is actuated by control module 114 as describedabove with respect to FIG. 1. When actuated, the flying shear 308 movesat the same speed of the material being fed through the apparatus 300and causes the parts of the material to be sheared apart along with anyprescribed apertures or notches as formed with the press 108 describedabove with respect to FIG. 1.

FIG. 4 depicts another embodiment of a gutter cover forming apparatus400. The apparatus 400 is similar to the apparatus 100 of FIG. 1 exceptthat the press 106 is replaced with a sprocket former 406. In thisembodiment, the feeder/straightener 104 is set to feed a full length ofmaterial that, when complete, actuates the press 108 to cut the materialand form any apertures or notches as described above with respect toFIG. 1. The material is then passed from the press 108 to the sprocketformer 406. As the material passes through the sprocket former 406,housing feed and guide rollers engage the material and a rotatingsprocket forms apertures in the material similar to those formed by thepress 106 as described above with respect to FIG. 1. The control module114 controls the operation of the sprocket former 406 to cause thesprockets to be engaged and disengaged. It is recognized that thoseskilled in the art may choose to actuate the sprocket former 406 viaother means such as micro switches. The material is then guided into theroll former 110 where the part is completed as described above withrespect to FIG. 1.

FIG. 5 depicts another embodiment of a gutter cover forming apparatus500. The apparatus 500 is similar to the apparatus 100 of FIG. 1 exceptthat the press 108 is replaced with a flying shear 508. In thisembodiment, the flying shear 508 is located after the roll former 110and otherwise is similar to the flying shear 308 described above withrespect to FIG. 3. In operation, the flying shear 508 cuts the materialto a desired length as well as forms the notches and apertures formed bythe press 108 as described above with respect to FIG. 1.

FIG. 6 depicts another embodiment of a gutter cover forming apparatus600. The apparatus 600 is similar to the apparatus 100 of FIG. 1 exceptthat the press 106 is replaced by a sprocket former 606 and the press108 is replaced by a flying shear 608. The flying shear 608 may belocated after the roll former 110. Alternatively, the flying shear 608may be located between the sprocket former 606 and the roll former 110.

It is contemplated that other variations to any of the embodiments ofthe above-disclosed apparatus may be made without departing from thescope of the invention. For example, alternative material guidancesystems may be utilized or incorporated into components of the apparatusthat would eliminate the need for the feeder and/or the straightener. Inone example, the sprocket former 606 of the embodiment disclosed in FIG.6 could be devised to also function as a feeder/straightener, therebyeliminating the need for the feeder/straightener 104. Moreover, thematerial being worked upon may be fed into the apparatus in pre-cutlengths of flat stock, thereby eliminating the need for the uncoiler 102and the straightener portion of the feeder/straightener 104. Othervariants may further be devised by those skilled in the art withoutdeparting from the spirit of the invention.

Thus, a novel manufacturing apparatus and method are disclosed hereinfor fabricating articles having apertures from a flat feedstock. Thepresent invention overcomes the disadvantages associated with the priorart. Specifically, the present invention includes equipment used forfabricating gutter covers which is light in weight as compared to theconventional equipment presently used. The inventive apparatus caneasily be moved and installed with typical equipment used inwarehousing, such as a fork lift.

While the foregoing is directed to embodiments of the present invention,other and further embodiments of the invention may be devised withoutdeparting from the basic scope thereof, and the scope thereof may bedetermined by the following claims.

1. An apparatus for fabricating articles having apertures from a flatfeedstock, comprising: an uncoiler for supplying a flat feedstock inroll form; a feeder/straightener for receiving the feedstock from theuncoiler; a first press for receiving the feedstock from thefeeder/straightener, the first press housing a tool and die that formsone or more apertures in the feedstock; a second press for receiving thefeedstock from the first press, the second press housing a tool and diethat cuts the feedstock into a finished length; and a roll former forreceiving the feedstock from the second press, the roll formercomprising a plurality of rollers that create a desired profile alongthe width of the feedstock.
 2. The apparatus of claim 1, wherein thefirst and second presses are about two-ton presses or smaller.
 3. Theapparatus of claim 1, wherein the second press is configured to form oneor more apertures in the feedstock.
 4. The apparatus of claim 1, whereinthe second press is configured to form one or more notches along an edgeof the feedstock.
 5. The apparatus of claim 1, wherein the second pressis configured to form one or more apertures and one or more notches inthe feedstock while cutting the feedstock into a finished length.
 6. Theapparatus of claim 1, wherein the roll former further comprises a set offeed rollers configured to pull the finished length feedstock into theroll former.
 7. The apparatus of claim 1, further comprising: acollection table disposed proximate an exit side of the roll former,such that the finished length feedstock can be dropped into thecollection table as it exits the roll former during operation.
 8. Theapparatus of claim 1, further comprising: a control module configured tocontrol the one or more of the uncoiler, the feeder/straightener, thefirst press, the second press, or the roll former.
 9. The apparatus ofclaim 8, wherein the controller counts each part manufactured.
 10. Theapparatus of claim 8, wherein the controller further includes a computerreadable medium containing instructions that, when executed, cause theapparatus to fabricate sections of a rain gutter cover having aplurality of apertures and that overlap and may be fastened togetherproximate cut edges of the feedstock to form a gutter cover having adesired length.
 11. An apparatus for fabricating articles havingapertures from a flat feedstock, comprising: an uncoiler for supplying aflat feedstock in roll form; a feeder/straightener for receiving thefeedstock from the uncoiler; a press for receiving the feedstock fromthe feeder/straightener, the press configured to form one or moreapertures in the feedstock and to cut the feedstock into a finishedlength; and a roll former for receiving the feedstock from the press,the roll former comprising a plurality of rollers that create a desiredprofile along the width of the feedstock.
 12. The apparatus of claim 11,wherein the press has a size of up to about 10 tons.
 13. The apparatusof claim 11, wherein the press further comprises: a first tool and dieconfigured to form from one or more apertures with each stroke of thepress; and a retractable second tool and die comprising one or moreindependent sections configured to cut the feedstock into a finishedlength and to make at least one of one or more apertures or one or morenotches proximate cut edges of the feedstock.
 14. The apparatus of claim13, wherein the retractable second tool and die is configured to createboth one or more apertures and one or more notches proximate cut edgesof the feedstock simultaneously in the part of the feedstock being cutinto a finished length and the remaining portion of the feedstock. 15.The apparatus of claim 11, further comprising: a collection tabledisposed proximate an exit side of the roll former, such that thefinished length feedstock can be dropped into the collection table as itexits the roll former during operation.
 16. The apparatus of claim 11,further comprising: a control module configured to control the one ormore of the uncoiler, the feeder/straightener, the press, or the rollformer.
 17. The apparatus of claim 16, wherein the controller furtherincludes a computer readable medium containing instructions that, whenexecuted, cause the apparatus to fabricate sections of a rain guttercover having a plurality of apertures and that overlap and may befastened together proximate cut edges of the feedstock to form a guttercover having a desired length.
 18. A method of fabricating articleshaving apertures from a flat feedstock, comprising: providing, inalignment, an uncoiler for supplying a flat feedstock in roll form, afeeder/straightener for receiving the feedstock from the uncoiler, afirst press for receiving the feedstock from the feeder/straightener,and a roll former for receiving the feedstock from the press; meteringout a desired quantity of a flat feedstock in roll form from theuncoiler to the feeder/straightener; forming one or more apertures inthe straightened feedstock using the first press; cutting the feedstockinto a finished length; and creating a desired profile along the widthof the feedstock using the roll former.
 19. The method of claim 18,wherein the feedstock is cut into a finished length using the firstpress.
 20. The method of claim 18, wherein a second press is providedbetween the first press and the roll former and wherein the feedstock iscut into a finished length using the second press.